Fire, thermal, and/or sound resistant confined space construction

ABSTRACT

A structure having a confined space. The structure includes: (a) a first building unit, (b) a second building unit, (c) a confined space located between the building units, and (d) a structure connecting the fire resistance rated, confined space to the first unit and the second unit. The confined space includes: (i) an interior support structure, (ii) an outer membrane on each side of the interior support structure, (iii) a substantially organic material between the outer membranes, and (iv) at least one secondary support member attached to the interior support structure for preventing bowing of the outer membranes. The confined space provides fire, sound, or thermal resistance and combinations thereof.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates generally to a structure having a confinedspace and, more particularly, to a confined space located in a web trussassembly, the confined space being filled with an organic containingmaterial having a minimum installed density for preventing gaps. Theconfined space provides fire, sound, or thermal resistance, orcombinations thereof.

(2) Description of the Prior Art

Multi-family residential constructions typically include separationwalls and floors constructed of wood members and having an insulatingmaterial between the units. These wood members may include dualtwo-by-four framing with a drywall surface on both sides of the framing.In many cases, this type of construction requires that the drywall beattached to an interior surface in a gap in the framing after theframing is placed upright to serve as a wall. After the framing isplaced upright, material may be positioned in the framing, and later anadditional drywall membrane is fastened to the outside of the framing tocomplete an interior wall. This process is expensive, labor-intensiveand time consuming.

One purpose of such a construction of a confined space is to provide afire resistance separation between adjacent spaces to meet federal,state and local regulations concerning the fire resistance of such aconstruction. Underwriters Laboratories Inc. (UL), an independent,not-for-profit product safety testing and certification organization,has been testing products for public safety for more than a century.Because UL has an undisputed reputation as the leader in U.S. productsafety and certification, it is advantageous to obtain classification ofa building product by UL. One UL test, ANSI/UL 263 (ASTM E119 and NFPA251), involves rating such separation walls and floors for fireresistance. U-370 sets forth the construction of separation walls andfloors including only an outer membrane sufficiently fire resistant togain UL classification for two-hour fire resistance. U-370 separationwalls and floors are less costly to construct than a conventionalseparation wall.

A similar problem exists in the confined space between the walls orfloors of a building. Those structures may be filled with insulation,such as cellulose, which is fire retardant. The insulation in floors isadded for thermal or acoustic insulation reasons. However, once an outermembrane is attached to the studs or truss, the insulation therein maycause bowing of the outer membrane.

Thus, there is a need for a structure having a confined space. Thestructure includes a first building unit and second building unit. Aconfined space is located between the building units. The confined spaceis filled with an organic containing material having a minimum installeddensity for preventing gaps, and support members for preventing bowingof drywall once insulation is installed.

SUMMARY OF THE INVENTION

The present invention is directed to a structure having a confinedspace. The confined space may be fire resistance rated, and may befilled with a substantially organic material barrier of a minimuminstalled density of about ½ pound per cubic foot. The structure mayinclude: (a) a first building unit, (b) a second building unit, (c) aconfined space located between the building units, and (d) a structureconnecting the confined space to the first unit and the second unit. Theconfined space may include: (i) an interior support structure, (ii) anouter membrane on each side of the interior support structure, (iii) asubstantially organic material between the outer membranes, and (iv) atleast one secondary support member attached to the interior supportstructure for preventing bowing of the outer membranes.

In the preferred embodiment, the first building unit may be anoccupiable space. The occupiable space may be a residential space suchas a town home. The residential space may also be a first floor of abuilding.

Also in the preferred embodiment, the second building unit may be anoccupiable space. The occupiable space may be residential such as astacked condominium, town home or a second floor. The structure mayinclude a “wall” attached to the “left” edge of the confined space and awall attached to the “right” edge of the confined space.

In one embodiment, the interior support structure may include aplurality of structural interior support members. The structuralinterior support members may include a plurality of “transverse” (Arethe quotations marks on transverse necessary, please delete if not)members. The plurality of “transverse” members may be spaced apart.Further, the plurality of “transverse” members may be spaced apart nomore than about 16 inches. In one embodiment, the plurality of“transverse” members may further include cross bracing at about the midspan of the plurality of “transverse” members.

Preferably, at least one of the outer membranes may be fire resistantwallboard such as a gypsum wallboard (GWB) Type X or Type C as definedin ASTM C11. The gypsum wallboard preferably conforms to ASTM TestC-36-96.

In the preferred embodiment, the substantially organic material may beselected from the group consisting of fibrous material, granularmaterial, pellet material, aggregated material, agglomerated material,closed cell foam, open cell foam, fire retardants, binders and mixturesthereof. The substantially organic material may be a natural material.The natural material may be cellulosic. Further, the substantiallyorganic material may be an acoustically non-conductive material.

In an embodiment, the substantially organic containing material may alsoinclude an inorganic material. The inorganic material is selected fromthe group consisting of fiberglass, rock wool, pearlite, mineral wool,asbestos, cementitious materials, fire retardants, binders and mixturesthereof.

In the preferred embodiment, the secondary support member may be aresilient channel, pallet strapping, or a furring strip.

Accordingly, one aspect of the present invention is to provide astructure having a confined space. The structure may include: (a) afirst building unit, (b) a second building unit, and (c) a confinedspace located between the building units, the confined space beingfilled with an organic containing material having a minimum installeddensity for preventing gaps having only outer membranes. The confinedspace may provide fire, sound, or thermal resistance and combinationsthereof. The confined space may provide improved fire, sound, or thermalresistance over existing structures, such as those which includesprinkler systems for fire control.

Another aspect of the present invention is to provide an organiccontaining material confined space for a structure. The confined spacemay include: (a) an interior support structure, (b) an outer membrane oneach side of the interior support structure, (c) a substantially organicmaterial between the outer membranes, and (d) at least one secondarysupport member attached to the interior support structure for preventingbowing of the outer membranes. The confined space may provide fire,sound, or thermal resistance and combinations thereof.

Still another aspect of the present invention is to provide a structurehaving a confined space. The structure may include: (a) a first buildingunit, (b) a second building unit, (c) a confined space located betweenthe building units, and (d) a structure connecting the fire resistancerated, confined space to the first unit and the second unit. Theconfined space may include: (i) an interior support structure, (ii) anouter membrane on each side of the interior support structure, (iii) asubstantially organic material between the outer membranes, and (iv) atleast one secondary support member attached to the interior supportstructure for preventing bowing of the outer membranes. The confinedspace may provide fire, sound, or thermal resistance and combinationsthereof.

These and other aspects of the present invention will become apparent tothose skilled in the art after a reading of the following description ofthe preferred embodiment when considered with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a structure having a confinedspace constructed according to the present invention;

FIG. 2 is a perspective view of a confined space constructed accordingto an embodiment of the present invention;

FIG. 3 is a perspective view of a confined space constructed accordingto an embodiment of the present invention; and

FIG. 4 is a cross-sectional view of a confined space constructedaccording to an embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the following description, like reference characters designate likeor corresponding parts throughout the several views. Also in thefollowing description, it is to be understood that such terms as“forward,” “rearward,” “left,” “right,” “upwardly,” “downwardly,” andthe like are words of convenience and are not to be construed aslimiting terms.

Referring now to the drawings in general and FIG. 1 in particular, itwill be understood that the illustrations are for the purpose ofdescribing a preferred embodiment of the invention and are not intendedto limit the invention thereto.

As best seen in FIG. 1, a structure having a confined space, generallydesignated 10, is shown constructed according to the present invention.In the preferred embodiment, the confined space is fire resistancerated. The confined space may also provide “improved” thermal resistanceand acoustic transmission resistance.

The structure having a confined space includes a first building unit 13and a second building unit 15. Additional building units 12 may also bepart of the structure. The first building unit 12 and the secondbuilding unit 15 may be occupiable spaces, which may be residentiallyoccupiable spaces such as town homes, stacked condominiums, or a firstfloor and a second floor of a building. A town home is generally definedby the 2000 International Residential Code as a single-family dwellingunit constructed as a group of three or more attached units in whicheach unit extends from foundation to roof with open space on at leasttwo sides. A confined space 18, constructed according to the presentinvention, may be located between each building unit 12, 13, 15. In apreferred embodiment, the confined space 18 is fire resistance rated.FIG. 2 is a perspective view of the confined space 18 shown in FIG. 1with a structure 20 connecting the first building unit 13 and the secondbuilding unit 15. The structure 20 connecting the first building unit 13to the second building unit 15 includes a wall assembly 28 attached tothe right edge of the confined space 18 and a wall assembly 30 attachedto the left edge of the fire resistance rated, confined space.

The structure may include wiring, plumbing, HVAC, venting, sprinklersystems, and other systems.

As seen in FIGS. 3 and 4, the confined space 18 includes an interiorsupport structure 22 and a substantially organic material 26 between theouter membranes 24. The interior support structure 22 includes aplurality of structural interior support members 32. The independentinterior support members 32 include a plurality of substantiallyhorizontal members 34. The plurality of substantially horizontal members34 are spaced apart. The plurality of substantially horizontal members34 are spaced apart no more than about 16 inches. The plurality ofsubstantially horizontal members 34 further include cross bracing 36 atabout the mid span of the plurality of substantially horizontal members34.

The fire resistance rated, confined space may also include secondarysupport members 38. Preferably, the secondary support member 38 is aflexible member such as a resilient channel. The secondary supportmember 38 may also be a pallet strapping. In one embodiment, thesecondary support member 38 is a furing strip. The secondary supportmember 38 helps prevent bowing of the outer membrane 24. The secondarysupport members may also be used to hold a tertiary support member. Thetertiary support member may be a conventional netting to assist inholding the organic material in place until the drywall is installed(not shown).

The substantially organic material 26 is selected from the groupconsisting of fibrous material, granular material, pellet material,aggregated material, agglomerated material, closed cell foam, open cellfoam, fire retardants, binders and mixtures thereof. The substantiallyorganic material 26 is a natural material. Preferably, the naturalmaterial is cellulosic. In one embodiment, the substantially organicmaterial 26 is an acoustically transmission resistive material.

The substantially organic material 26 may further include inorganicmaterial. The inorganic material may be selected from the groupconsisting of fiberglass, rock wool, pearlite, mineral wool, asbestos,cementitious materials, fire retardants, binders and mixtures thereof.

In a preferred embodiment, the organic containing material may be anorganic containing material having a verified minimum installed densityof greater than about ½ pound per cubic foot. When the confined space isfire resistance rated, the minimum installed density of the organiccontaining material must be verified. The verified density helps preventair gaps and thus helps prevent the spread of fire.

As seen in FIG. 4, at least one of the outer membranes 24 is fireresistant wallboard. The fire resistant wallboard is a gypsum wallboard(GWB) Type X or Type C as defined in ASTM C11. The gypsum wallboardconforms to ASTM Test C-36-96. Also, the confined space 18 may includeat least one outer membrane 24 on each side of the interior supportstructure 22.

Certain modifications and improvements will occur to those skilled inthe art upon a reading of the foregoing description. By way of example,the structure may include plumbing, HVAC, electrical or other buildingsystems. Multiple membranes may be incorporated to allow increased fireresistive, thermal or acoustic resistive properties. The structure mayinclude drywall or other materials along the sides of the structureperiphery to allow increased fire resistive, thermal or acousticresistive properties. The transverse or horizontal members may be webtruss assemblies, wood studs (either pre-fabricated or made on site),composite I-joists or other similar weight bearing members.

It should be understood that all such modifications and improvementshave been deleted herein for the sake of conciseness and readability butare properly within the scope of the following claims.

1. A structure having a confined space, the structure comprising: (a) afirst building unit; (b) a second building unit; and (c) a confinedspace located between the building units, the confined space beingfilled with an organic containing material having a minimum installeddensity for preventing gaps, whereby the confined space provides fire,sound, or thermal resistance and combinations thereof.
 2. The structureaccording to claim 1, further including a structure connecting theconfined space to the first unit and the second unit.
 3. An organiccontaining material confined space for a structure, the confined spacecomprising: (a) an interior support structure; (b) at least one outermembrane on each side of the interior support structure; (c) asubstantially organic material between the outer membranes; and (d) atleast one secondary support member attached to the interior supportstructure for preventing bowing of the outer membranes, whereby theconfined space provides fire, sound, or thermal resistance andcombinations thereof.
 4. The confined space according to claim 3,wherein the interior support structure includes a plurality ofstructurally independent interior support members.
 5. The confined spaceaccording to claim 4, wherein the structurally independent interiorsupport members include a plurality of substantially horizontal membersand.
 6. The confined space according to claim 5, wherein thesubstantially horizontal members are spaced apart.
 7. The confined spaceaccording to claim 6, wherein the substantially horizontal members arespaced apart no more than about 16 inches.
 8. The confined spaceaccording to claim 3, wherein at least one of the outer membranes isfire resistant wallboard.
 9. The confined space according to claim 8,wherein the fire resistant wallboard is a gypsum wallboard (GWB) Type Xor Type C as defined in ASTM C11(Committee C11 on Gypsum and RelatedBuilding Materials and Systems).
 10. The confined space according toclaim 9, wherein the gypsum wallboard conforms to ASTM Test C-36-96. 11.The confined space according to claim 3, wherein the substantiallyorganic material is selected from the group consisting of fibrousmaterial, granular material, pellet material, aggregated material,agglomerated material, closed cell foam, open cell foam, fireretardants, binders and mixtures thereof.
 12. The organic containingmaterial according to claim 3, wherein the organic containing materialfurther includes an inorganic material.
 13. The confined space accordingto claim 12, wherein the inorganic material is selected from the groupconsisting of fiberglass, rock wool, pearlite, mineral wool, asbestos,cementitious materials, fire retardants, binders and mixtures thereof.14. The confined space according to claim 3, wherein the substantiallyorganic material is a natural material.
 15. The confined space accordingto claim 14, wherein the natural material is cellulosic.
 16. Theconfined space according to claim 3, wherein the substantially organicmaterial is an acoustically transmission resistive material.
 17. Theconfined space according to claim 3, wherein the secondary supportmember includes a resilient channel.
 18. The confined space according toclaim 3, wherein the secondary support member includes a flexiblematerial.
 19. The confined space according to claim 18, wherein theflexible material is pallet strapping.
 20. The confined space accordingto claim 3, wherein the secondary support member includes a faringstrip.
 21. The confined space according to claim 3, wherein there is atertiary support for holding the organic material in place until thegypsum wallboard is added.
 22. A structure having a confined space, thestructure comprising: (a) a first building unit; (b) a second buildingunit; (c) a confined space located between the building units, theconfined space including: (i) an interior support structure; (ii) anouter membrane on each side of the interior support structure; (iii) asubstantially organic material between the outer membranes; and (iv) atleast one secondary support member attached to the interior supportstructure for preventing bowing of the outer membranes; and (d) astructure connecting the confined space to the first unit and the secondunit, whereby the confined space provides fire, sound, or thermalresistance and combinations thereof.
 23. The structure according toclaim 22, wherein the structure includes a wall assembly attached to theleft edge of the confined space and a wall assembly attached to theright edge of the fire resistance rated, confined space.
 24. Thestructure according to claim 22, wherein the building units are anoccupiable space.
 25. The structure according to claim 24, wherein theoccupiable space is residential.